Process for forming a table top

ABSTRACT

A method of forming a table top comprises providing a skin-support frame, forming a lower skin portion of the table top, forming an upper skin portion of the table top such that the upper skin portion has a visual characteristic different from a visual characteristic of the lower skin portion.

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/743,423, filed Mar. 7, 2006, which is expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to a table top, and particularly to a process for forming a table top.

SUMMARY

According to the present disclosure, a method of forming a table top comprises the steps of providing a skin-support frame, forming a lower skin portion of the table top, forming an upper skin portion of the table top such that the upper skin portion has a visual characteristic different from a visual characteristic of the lower skin portion, and positioning the upper skin portion and lower skin portion relative to each other so as to provide an interior region containing the skin-support frame. Illustratively, the visual characteristic is a color so that the upper skin portion has a first color and the lower skin portion has a second color different from the first color. In other examples, the visual characteristic may be in the form of a different texture, wood grain pattern, or the like.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:

FIG. 1 is a diagrammatic view of a table top including an upper skin and a lower skin cooperating with the upper skin to form an interior region containing a skin-support frame during one step of the present process;

FIG. 2 is a diagrammatic view of a skin-formation system in accordance with the present disclosure for forming the upper and lower skins;

FIG. 3 is a sectional view showing another table top in accordance with the present disclosure, which table top includes an upper skin or preform adapted to be fitted onto and coupled to a lower skin of a sub-assembly of the table top;

FIG. 4 is a sectional view similar to FIG. 3 showing the upper skin coupled to the lower skin such that a side wall of the upper skin overlaps and mates against a side wall of the lower skin to define a partition or parting line therebetween exposing a lower portion (i.e., “reveal”) of the side wall of the lower skin and showing that the exposed lower portion of the lower skin side wall has a second characteristic that is different from and in contrast with a first characteristic of the side wall of the upper skin;

FIG. 5 is a sectional view (similar to FIG. 4) of another table top in accordance with the present disclosure showing a parting line of the table top of FIG. 4 raised (as compared to the parting line shown in FIG. 3) to expose a larger portion (i.e., reveal) of the side wall of the lower skin; and

FIGS. 6 and 7 are sectional views of two more table tops having upper and lower skins with different characteristics.

DETAILED DESCRIPTION

A table top 10 includes a table top skin unit 12 enclosing a frame 14 of table top 10, as shown, for example, diagrammatically in FIG. 1. Skin unit 12 includes an upper skin 16 having a first characteristic 18. A lower skin 20 of skin unit 12 has a second characteristic 22 different from the first characteristic 18. Illustratively, first characteristic 18 is a first color and second characteristic 22 is a second color different from the first color. In other examples, first and second characteristics 18, 22 may be different textures, wood grain patterns, or the like. As such, characteristics 18, 22 may be different colors, textures, wood grain patterns, or any combination thereof

Upper skin 16 includes a top surface 17 and an edge surface 19. As suggested in FIG. 1, upper skin 16 is coupled to lower skin 20 to form table top 10. Edge surface 19 is arranged to peripherally surround top surface 17 to form an interior region 21 therebetween.

Lower skin 20 includes a bottom surface 15 and an edge surface 29. As suggested in FIG. 1, lower skin 20 is coupled to upper skin 16 to form table top 10. Edge surface 29 is arranged to peripherally surround bottom surface 15 to form interior region 21 therebetween.

Table top 10 is formed by positioning upper and lower skins 16, 20 relative to each other such that a portion of each edge surface 19, 29 is exposed and positioning frame 14 to lie in interior region 21. After the positioning of upper and lower skins 16, 20, coupling of upper skin 16 to lower skin 20 completes the process.

A skin-formation system 24 in accordance with the present disclosure may be used to form each skin 16, 20, as shown, for example, in FIG. 2. System 24 comprises a strip extruder 26 that extrudes a strip 28 of plastics material (e.g., ABS—acrylonitrile butadiene styrene). System 24 may include a colorant dispenser 30 for adding a color to strip 28 to provide a visual thereof. In some examples, system 24 may have a film applicator 32 arranged to apply on a surface of strip 28 a thin film having a predetermined pattern, such as, for example, a wood grain pattern or otherwise, to provide a visual characteristic thereon.

Cooling rollers, strip movers, and any number of other strip-treatment devices may be included in system 24. For example, system 24 may be configured to coordinate the constant output of extruder 26 with the “batch” processing of a shape former 34 (e.g., a thermoformer or a vacuum former) downstream from extruder 26 relative to movement of strip 28. In other examples, system 24 may have a strip cutter (not shown) arranged to cut strip 28 into individual sheets to be subsequently fed to shape former 34.

Shape former 34 is configured to form strip 28 or individual sheets thereof into the desired shape for the respective skin 16, 20. Former 34 may be used to form a texture in skin 16, 20.

A single shape former 34 may be used for each skin 16, 20 by use of different molds in the case where skins 16, 20 have different shapes or the same mold may be used for each skin 16, 20 in cases where skins 16, 20 have the same shape. In other examples, multiple shape formers 34 may be used to form skins 16, 20.

As suggested above, shape former 34 may be, for example, a thermoformer or a vacuum former. In the case of a thermoformer, the thermoformer is configured to thermoform strip 28 or sheets thereof into the desired shape by use of heat and mechanical pressure. In the case of a vacuum former, the vacuum former is configured to form strip 28 or sheets thereof into the desired shape by use of heat and vacuum pressure.

Shape former 34 may be configured in any number of other ways to form skins 16, 20. For example, former 34 may form skins 16, 20 by blow-molding, or injection-molding, to name just a few.

A trimmer (not shown) may be included in system 24 downstream from shape former 34. In such a case, the trimmer is used to trim excess material from skins 16, 20.

Table top 10 is assembled after formation of skins 16, 20. To do so, frame 14 and, in some cases, a core associated with frame 14 are placed on lower skin 20. In cases where there is a core, frame 14 extends along a periphery of lower skin 20 adjacent to edge surface 29 and the core is placed within frame 14. Upper skin 16 is then coupled to lower skin 20 to retain frame 14 (and an associated core) in interior region 21 formed between skins 16, 20 to complete the assembly.

A table top 110 includes a skin unit 112 having an upper skin 116 and a lower skin 120, as shown, for example, in FIGS. 3 and 4. Upper skin 116 has first characteristic 18 and lower skin 120 has second characteristic 22 different from first characteristic 18, 22. Illustratively, first characteristic IS of upper skin 116 may be a color, as suggested by a colorant 127 added to upper skin 116, or may be a film 125 applied to a surface of upper skin 116. In other examples, first characteristic 18 may be a texture applied to upper skin 116.

Lower skin 120 is formed of a plastics material (e.g., ABS) surrounding a core 126 (e.g., honeycomb or corrugated). A tubular frame 114 may extend along a periphery 130 of lower skin 120 to peripherally surround core 126. Lower skin 120 may be formed by use of extruder 26 in combination with a die (not show) to produce the cross-section of lower skin 120. End caps (not shown) or other closures may be added to the ends of lower skin 120 to close the ends thereof. Other manufacturing methods may be used to form lower skin 120 to have the illustrated enclosure shape.

Upper skin 116 is formed of a plastics material (e.g., ABS) by use of the system 24. Shape former 34 forms skin 116 to have a peripheral wall or edge surface 128 including first characteristic 116.

During assembly of table top 110, upper skin 116 is fitted onto skin 120 such that edge surface 128′ overlaps and mates against a peripheral wall or edge surface 130 of lower skin 120, as shown, for example, in FIGS. 3 and 4. Edge surface 128′ and edge surface 130 are coupled to one another by a suitable coupling mechanism such as, for example, glue, adhesive, or ultrasonic welding. A partition 123 in the form of a parting line is defined between edge surface 128′ and edge surface 130 to expose a lower portion or reveal 132 of edge surface 130 having second characteristic 22 contrasted against first characteristic 18 of edge surface 128′. Upper skin 116 can be formed to provide a smaller edge surface 128 a shown, for example, in FIG. 5 that exposes a larger portion of edge surface 130 so that second characteristic 22 is more visible to an observer of table top 110.

In the embodiment shown in FIG. 5, edge surface 128′ of upper skin 116′ has a shorter height as compared to edge surface 128 of upper skin 116 shown in FIGS. 3 and 4. When upper skin 116′ is coupled to lower skin 120′, the height of the resulting exposed lower portion or reveal 132′ of lower skin 120′ is greater than the height of reveal 132 shown in FIG. 4.

A table top 210 includes a skin unit 212 having an upper skin 216 and a lower skin 220, as shown, for example, in FIG. 6. Upper skin 216 has first characteristic 18 and lower skin 220 has second characteristic 22 different from first characteristic 18, 22. Illustratively, first characteristic 18 of upper skin 216 may be a color, as suggested by a colorant 227 added to upper skin 216, or may be a film 225 applied to a surface of upper skin 216. In other examples, first characteristic 18 may be a texture applied to upper skin 216.

Upper and lower skins 216, 220 are coupled to one another along the periphery of table top 210. An edge surface 228 of upper skin 216 is coupled to an edge surface 230 of lower skin 220 by a suitable mechanism such, as for example, glue, adhesive, or ultrasonic welding. A partition 223 in the form of a parting line is defined between edge surface 228 and edge surface 230 to expose a lower portion or reveal 232 of edge surface 230 having second characteristic 22 contrasted against first characteristic 18 of edge surface 228.

Skins 216, 220 cooperate to define an interior region 221. Interior region 221 contains a core 227 (e.g., corrugated or honeycomb) surrounded by a frame 214 extending along the periphery of table top 210.

A table top 310 includes a skin unit 312 having an upper skin 316 and a lower skin 320, as shown, for example, in FIG. 7. Upper skin 316 has first characteristic 18 and lower skin 320 has second characteristic 22 different from first characteristic 18, 22. Illustratively, first characteristic 18 of upper skin 316 may be a color, as suggested by a colorant 327 added to upper skin 316, or may be a film 325 applied to a surface of upper skin 316. In other examples, first characteristic 18 may be a texture applied to upper skin 316.

Upper and lower skins 316, 320 include edge surfaces 328, 330. Edge surfaces 328, 330 cooperate to form a slot 329 therebetween. A partition 323 in the form of a T-shaped bumper 323 extends through slot 329 into a slot 331 formed in a peripherally-extending frame 314 mounted in an interior region 321 defined between skins 316, 320. A core 321 (e.g., corrugated or honeycomb) is located in interior region 321 and surrounded by frame 314. Edge surfaces 328, 330 exhibit first and second characteristics 18, 22 for viewing by an observer of table top 310.

In illustrative embodiments, frame 314 and core 321 are glued to lower skin 320 to align slot 331. Similarly, upper skin 316 is glued to an upper surface of frame 314 and core 321 to form slot 329. A portion of T-shaped bumper 323 is arranged to extend through slot 329 and into slot 331. 

1. A method of forming a table top, the method comprising providing a skin-support frame, forming a lower skin portion of a table top having an edge surface peripherally surrounding a bottom surface of the lower skin portion to form an interior region, forming an upper skin portion of the table top having an edge surface peripherally surrounding a top surface of the upper skin portion to form an interior region and such that the upper skin portion has a visual characteristic different from a visual characteristic of the lower skin portion, positioning the upper and lower skin portions relative to each other such that a portion of each edge surface is exposed and the skin supporting frame lies in the interior region of the upper and lower skin portions, and coupling the upper skin portion to the lower skin portion.
 2. The method of claim 1, wherein the upper skin portion visual characteristic is a color and the lower skin visual characteristic is another color different than the color of the upper skin portion.
 3. The method of claim 2, wherein the upper skin portion and the lower skin portion are formed of a plastics material and the color is a colorant uniformly dispersed throughout the extent of the plastics material.
 4. The method of claim 1, wherein the visual characteristic of the upper and lower skin portions is a film coupled to an upper and lower skin portion surface, the film having a predetermined imprinted pattern.
 5. The method of claim 4, wherein the predetermined pattern imprinted on the film is a wood grain pattern.
 6. The method of claim 1, wherein the upper skin portion visual characteristic and lower skin visual characteristic is a texture formed on the upper and lower skin portions.
 7. The method of claim 1, wherein the upper skin portion is ultrasonically welded to the lower skin portion to provide the table top.
 8. The method of claim 1, wherein the upper and lower skin portions are positioned relative to each other such that the edge surfaces partially overlap.
 9. The method of claim 1, wherein the lower skin portion surrounds the skin-support frame.
 10. The method of claim 1, further including a T-shaped bumper, and wherein the upper and lower skin portion edge surfaces cooperate to form a slot arranged to receive a portion of the T-shaped bumper.
 11. A method of forming a table top, the method comprising providing a skin-support frame including a tubular frame arranged to peripherally surround a core, forming a lower skin portion of a table top arranged to surround the skin-support frame including an edge surface peripherally surrounding a bottom surface of the lower skin portion, forming an upper skin portion of the table top having an edge surface peripherally surrounding a top surface of the upper skin portion to form an interior region and such that the upper skin portion has a color different from a color of the lower skin portion, positioning the upper and lower skin portions relative to each other such that a portion of each edge surface is exposed, and coupling the upper skin portion to the lower skin portion such that the edge surfaces partially overlap.
 12. The method of claim 10, wherein the upper skin portion color and lower skin color is a film coupled to the upper skin portion and the lower skin portion, the film having a predetermined pattern imprinted on the film.
 13. The method of claim 12, wherein the predetermined pattern imprinted on the film is a wood grain pattern.
 14. The method of claim 11, wherein the core includes a corrugated material.
 15. The method of claim 11, wherein the upper skin portion visual characteristic and lower skin visual characteristic is a texture formed on the upper and lower skin portions.
 16. The method of claim 11, wherein the upper skin portion and the lower skin portion are formed of a plastics material and the color is a colorant uniformly dispersed throughout the extent of the plastics material.
 17. The method of claim 11, wherein the upper skin portion is ultrasonically welded to the lower skin portion to provide the table top.
 18. A method of forming a table top, the method comprising providing a skin-support frame including a tubular frame arranged to peripherally surround a core, the tubular frame formed to include a tab-receiving slot, forming a lower skin portion of a table top having an edge surface peripherally surrounding a bottom surface of the lower skin portion to form an interior region, forming an upper skin portion of the table top having an edge surface peripherally surrounding a top surface of the upper skin portion to form an interior region and such that the upper skin portion has a visual characteristic different from a visual characteristic of the lower skin portion, positioning the upper and lower skin portions relative to each other on the frame and coupling such that a portion of each edge surface is exposed and the skin supporting frame lies in the interior region of the upper and lower skin portions, coupling the upper skin portion to the lower skin portion such that the upper and lower skin portion edge surfaces cooperate to form a tab-receiving slot arranged in alignment relative to the tubular frame tab-receiving slot, and providing a T-shaped bumper extending into the tab-receiving slots.
 19. The method of claim 18, wherein the upper skin portion visual characteristic is a color and the lower skin visual characteristic is another color different than the color of the upper skin portion.
 20. The method of claim 18, wherein the visual characteristic of the upper and lower skin portions is a film coupled to an upper and lower skin portion surface, the film having a predetermined imprinted pattern. 